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Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit type part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market leader for fresh comfort products because of its quality and experience. Since early 2019, the vacuum provide to its tray sealer packaging machines has been exceptionally energy-efficient following the set up of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its convenience foods in a modern facility in Jagsthausen, a city within the German state of Baden-Württemberg. To permit it to provide fresh raw produce all 12 months round, the corporate has its own growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the complete product range could be supplied year-round, bought to finish users across Germany by way of supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, in addition to for third party manufacturers. Gartenfrisch Jung’s historical past dates back to 1795. What started out as a small piece of farmland has now remodeled into integrated, managed growers of salads and vegetables and one other arm for processing these products. As a household business, Gartenfrisch Jung has been passed from one era to the subsequent ever since it began. The experience gained in consequence has subsequently grown steadily, resulting in the company’s successful improvement and a prime quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked meals daily. This is equivalent to dealing with 2,000 pallets, which are then delivered to clients by eighty refrigerated vehicles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the previous, these packaging machines were outfitted with one rotary vane vacuum pump every, though one machine had two vacuum pumps. These 13 vacuum pumps have been used to evacuate the trays to the required vacuum stage prior to sealing. A two-shift operation is in place on all twelve packaging lines. The vacuum pumps ran continuously throughout these shifts, other than during breaks. During a third shift, the production facilities are cleaned while all equipment is stationary.
Jochen Neff, who is in command of know-how at Gartenfrisch Jung, was in search of an alternate vacuum supply, as a outcome of the warmth radiated by the 13 vacuum pumps was putting a pressure on the air con system within the manufacturing amenities, which are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum specialists from Busch Vacuum Solutions analyzed the situation and really helpful a centralized vacuum provide, which might be set up in a non-air-conditioned room exterior the manufacturing services.
Because Jung’s convenience merchandise have the best vacuum for packaging at a vacuum stage of 400 millibars, Busch really helpful using MINK claw vacuum pumps. This kind of vacuum pump has the highest efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which implies that the moving parts inside the vacuum pump do not are obtainable in contact with one another. In flip, no oil-based lubrication is required and all maintenance work associated to the utilization of oil as an working fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was geared up with a motor with a nominal motor rating of eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the same variety of working hours.
Centralizing the vacuum supply enabled the whole put in motor score to be reduced from 50.2 to sixteen kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. most power. This would correspond to a sixty eight percent discount in vitality consumption. However, in practice Jochen Neff has discovered that only one of the two MINK claw vacuum pumps is often in use and that this tends to run at a decreased rotational speed. After a quantity of months of use, Jochen Neff has measured average power consumption of 4 kilowatt hours for the whole vacuum supply. เกจวัดแรงดันน้ำประปาราคา is mainly linked to the fact that the twelve packaging strains do not all all the time run at maximum velocity and not all of the machines are in use on an everyday basis. The demand-based management system then decreases the rotational pace to reduce the output, which means that the system solely supplies the efficiency that’s truly required. In apply, this equates to energy savings of over 90 % for vacuum generation.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is connected to the packaging machines through a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every make sure that the required vacuum level is out there in the packaging chambers as quickly as it is needed within the packaging cycle. Removing the thirteen unique vacuum pumps from the production areas relieved strain from the air-con system. This meant that the air conditioning system could presumably be turned right down to keep the room temperature between 5 and 6 degrees Celsius. The savings in power costs on account of lowering the air conditioning output haven’t been measured. However, it could possibly generally be assumed that the change resulted in a big discount within the vitality consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, maintenance can be carried out on the person MINK claw vacuum pumps throughout production and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is proscribed primarily to the annual preventive change in gear oil. This is performed by a Busch service technician. With the centralized vacuum system, Jochen Neff has created a highly energy-efficient, dependable and economical vacuum supply for packaging his convenience products.
Fig: 1: One of twelve traces used to package deal convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the two vacuum vessels within the background
Fig. 3: Comparison of vitality consumption for a decentralized and centralized vacuum supply
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020
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